Pile fabric method



Oct. 11, 1955 PILE FABRIC METHOD 2 Sheets-Sheet 1 Filed Oct. 23, 1952 w T X o X o 5 x 2 X o X o X 0 X o o X o X o X o 5 X P X o 2 X o X o X o X o X X o X o X o L o X 8 9-3 X o 2 X 0 X o L L P XXXXXX I 3 XXXXooooo XXXXXXXXOoooo Looqooooooxxxx lNVEZ N TOR 22 Franz 144i. fioeJe/art en'ec -0 m ATTORNEYS.

Oct. 1955 F. w. E. HOESELBARTH ,720,222

PILE FABRIC METHOD 2 Sheets-Sheet 2 Filed Oct. 25, 1952 Snventor F'rarzz 14 6. HaeJeZZarf/i attorneys.

at least one adjoining wire.

. PILE FABRIC METHOD 3 Claims (Cl. 139-39) The present invention relates to woven pile fabrics, especially floor coverings of the type of. carpets and rugs.

This application has been divided and the subject mat ter relating to the pile fabric is embodied in divisional application Serial No. 490,816, filed February .28, 1955, for Pile Fabric. p 1

A purpose of the invention in a warp pile fabric is to obtain a contrast between groups of pile warp loops by providing highand low loops of 'contrasting warps in successive transverse rows, the high loops and low loops in each row being of the same height, and,to mask the lowloops of one row by high loops differently placed warpwise in the next row. t

'A furtherpurpose is to raise all the ends of difierent contrasting warps successively over different wires having high and low portions on each wire, the heights of the high portions being the same in the successive wires and the heights of the low portions being the same'in the successive wires, and to place the high portions dilferently on adjoining wires so that when the wires are withdrawn highfloopsof one transverse row will mask low loops of an adjoining transverse row, producing attractive con trasting effects along with texturing.

Further purposes appear inthe specification and in theclaims. t 4 "In the drawings 1 have chosen to illuustrate a. few only of the numerous embodiments in which my inven tion may appear, selecting the forms shown from the standpoints of convenience in illustration, satisfactory op oration and clear demonstration ofthe principles involved.

Figures 1, 2 and 3 are warpwise conventional, weave diagrams showing different weaves embodying theinven tion, with the wires still inplace.

Figure 4 is a top plan wire diagram showing a portion of a wire set in accordance with the invention.

Figure 5 is a fragmentary side elevation of a ,wire which is employed in producing the weave of theinvention.

Figure 6 is a photographic top plan view of axpil'e carpet produced in accordance with the invention. I

Very desirable textured eifects in carpets and rugs have been produced for many years by employing high and low loops in thesame transverse row. vIt is desirable to augment the attractive appearance by producing contrast in the appearanceof different pile warp ends without the expense incident to jacquard weaving.

1 In accordance with the present invention two or more contrasting pile warps are employed and the warps are raised over successive wires. All of the wires have high and low portions within the shed and the high portions on the successive wires are the same height and the low portions are of the same height. By placing the high portions differently weftwise on one wire with respect to adjoining wires, it is possible to obtain groups of high loops on one wire which adjoin groups of low loops on When the wires are withdrawn the high loops mask the low loops and thus by judicious choice of the locations of high and low loops on the successive wires it is possible to produce pattern effects, or haphazard or windblown appearances due to the fact that a particular pile warp in a particular row only produces visible or high loops at certain locations, while its low loops are masked at'other locations.

The number of different pile warps used will usually be two, although it will be understood that three or more alternating pile warps will in some cases be employed.

The pile warps may contrast by reason of any one of the following factors, which are suggestive of many other contrasting characteristics which will be employed:

1. The pile warps will in many cases be of different color.

2. The pile warps will in many cases be of dilferent material, for example one of rayon and one of wool, or one of rayon and oneof nylon, or one of a blend of wool and rayon and another of wool.

3. The pile warps will in many cases have a difference in pile density. For example one warp will have 200 ends in 27" while another warp will have 100 ends in 27" (in the thread-in certain dents will not have any ends).

4. The pile warps in many cases will have different reflectivity, even though the color is not diiferent. For example .one warp will be of polyvinylidene chloride and another of wool. t

5. The pile warps will in many cases be of diiferent construction, for example a heavy yarn in one warp and a light yarn in another warp.

It will be understood that the result of any one of these contrasting features is to accent the diiference between groups of pile warp ends, thus imparting an attractive appearance to the pile.

The weave employed may conform to any standard velvet or tapestry weave, whether of V, W or staggered W character, and the particular construction is not vital to the invention, although the invention exhibits a preferred embodiment in a V weave.

i As shown in a V weave in Figure l, a pair of pile warps 20 and 21 are raised successively over wires 22 extending transversely of the fabric, and each having high portions 23,all of which are of the same height in the successive wires and low portions 24 all of which are of the sameheight on the successive wires. The low portions areindicated by Xs in Figure 4 and the high portions by circles, and it will be seen that the high portions and low portions are placed difierently warpwise of the fabric on successive wires, according to a pattern, or according to a haphazard or helter-skelter arrangement as desired.

The; weave of Figure 1 has binder warps 26 and 27, a stuffer warp 28 and wefts 30 as well known.

. According to the weave shown in Figure 1, at the first step pile warp 20 is fully raised, binder warp 26 is raised half way and binder warp 27 pile warp 21 and stuffer warp 28 are lowered. A wire 22 is inserted in the upper shedfbetween pile warp 20 and binder warp 26 and a shot of weft is inserted in the lower shed between binder warp 26 on the one hand, and binder warp 27 pile warp 21 and stutter warp 28, on the other hand. On the next step, binder warp 27 remains lowered and all other warps are raised half way, forming a lower shed through which another shot of weft is taken.

on the next step pile warp 21 is fully raised and binderwarp 27 is raised half way forming an upper shed, while pile warp 20, binder warp 26 and stutter warp 28 are lowered forming a lower shed. A wire 22 is inserted in the upper shed, having the same height of high and low portions as the wire previously inserted, but having the high and low portions differently placed weftwise. A shot of weft is taken in the lower shed. The weave precedes this thus raising the contrasting warps successively.

When the wires are withdrawn without cutting, the low loops of each row are masked by the high loops in the adjoining row or rows, thus forming groups of high loops 31 of pile 21 and groups of high loops 32 of pile warp 20.

The invention is applicable to a W weave as shown in Figure 2.

In this case in the first step pile warp 20 is fully raised, binder warp 26 and pile warp 21 are raised half way, forming an upper shed, while binder warp 27 and stuifer warp 28 are lowered, forming a lower shed. A wavy wire 22 as previously described is inserted in the upper shed and a shot of weft is taken in the lower shed.

In the next step pile warp 26 and stutfer warp 28 are raised half way, while pile warp 20, pile warp 21 and binder warp 27 are lowered, forming a lower shed, and a shot of weft is taken in the lower shed.

In the next step pile warp 21 is fully raised while binder warp 27 and pile warp 20 are raised half way, forming an upper shed, and pile warp 26 and stuffer warp 28 are lowered, forming a lower shed. A wavy wire as previously described is inserted in the upper shed and a shot of weft is taken in the lower shed.

In the next step pile warp 27 and stuifer warp 28 are raised half way, while pile warp 20, pile warp 21 and binder warp 26 are lowered, forming a lower shed, and a shot of weft is taken in the lower shed. The weave then repeats, next raising pile warp 20 over another wavy wire as previously described.

The invention is also applicable to a staggered W-weave of the character described and claimed in my copending application, Serial No. 274,568, filed March 3, 1952, for Multiple Pile Staggered W-Weaving as shown in Figure 3.

In this case in the first step pile warp 20 is fully raised, while pile warp 21 and stuifer Warp 28 are raised half way, forming an upper shed, and binder warp 26 is lowered forming a lower shed. A wire of the character previously described is inserted in the upper shed and a shot of weft is taken in the lower shed. In the next step binder warp 26 is raised half way while all other warps are lowered and a shot of weft is taken in the lower shed thus formed.

In the next step pile warp 21 is fully raised, while pile warp 20 and stuffer warp 28 are raised half way forming an upper shed and binder warp 26 is lowered forming a lower shed. A wire as previously described is inserted in the upper shed and a shot of weft is taken in the lower shed.

In the next step binder warp 26 is raised half way while all other warps are lowered and a shot of weft is taken in the lower shed thus formed. The weave then repeats.

It will be evident that similar effects are obtained in the weaves of Figures 1, 2 and 3, except that in the weave of Figure 1 (the V weave) the bases of the loops are more widely spaced and a somewhat different appearance results therefrom.

The wire as shown in Figure may have any desired slope between the low portions 24 and the high portions 23, the slope in toward and away from the head preferably being gradual as shown at 33. The angle of slope both in the direction toward the head of the wire and in the direction away from the head of the wire as shown at 33 should preferably not exceed 25 and most desirably not exceed with respect to the longitudinal axis of the wire.

It will be evident that any suitable wire motion for inserting and withdrawing the transverse wires will be used as well known.

It will be evident that in the V-weave the pile warp is bound behind wefts not more frequently than every fourth weft and remains in the face at intervening points, while in the W-weave it is bound behind every other weft.

In view of my invention and disclosure variations and modifications to meet individual whim or particular need will doubtless become evident to others skilled in the art, to obtain all or part of the benefits of my invention without copying the method and apparatus shown, and I, therefore, claim all such insofar as they fall within the reasonable spirit and scope of my claims.

Having thus described my invention what I claim as new and desire to secure by Letters Patent is:

1. The method of weaving a pile carpet, using binder warp ends, stuffer warp ends, a plurality of sets of pile warp ends of different colors and wefts, which comprises raising all ends of one set of pile warp ends, raising other warp ends half way, thus forming an upper shed, lowering other warp ends, thus forming a lower shed, inserting into the upper shed a first non-cutting pile wire having high and low portions on its upper surface within the shed, inserting a shot of weft into the lower shed, beating up the wire and the weft, forming a new lower shed by readjusting the positions of the warp ends, inserting a shot of weft into the lower shed, beating up the weft, raising all ends of the other set of pile warp ends, raising other warp ends half way, thus forming an upper shed, lowering other warp ends, thus forming a lower shed, inserting into the upper shed a second noncutting pile wire having high and low portions within the shed on its upper surface and having the same heights of high and low portions as the first pile wire, but with the high and low portions differently placed weftwise from those on the first pile wire, inserting a shot of weft into the lower shed, beating up the weft and the wire, forming a new lower shed by readjusting the positions of the warp ends, inserting a shot of weft into the lower shed, beating up the weft, and withdrawing the wires and leaving uncut loops of varying heights in each row, the color of the low loops of one row being masked when viewed from the top by the high loops of a different color of the next row.

2. The method of claim 1, which comprises holding all of the ends of the first pile warp above the lower shed during the insertion of one weft prior to and one weft subsequent to the weft inserted with the first wire.

3. The method of claim 1, which comprises forming high loops on preceding and following rows on both sides of low loops on an intermediate row.

References Cited in the file of this patent UNITED STATES PATENTS 2,141,152 Kaufman Dec. 20, 1938 2,164,090 Shuttleworth June 27, 1939 2,430,559 Dacey Nov. 11, 1947 2,486,942 Groat Nov. 1, 1949 2,546,261 Groat Mar. 27, 1951 2,553,303 Crawford May 15, 1951 2,573,841 Groat Nov. 6, 1951 2,576,791 Jackson Nov. 27, 1951 2,650,621 Crawford Sept. 1, 1953 FOREIGN PATENTS 273,409 Great Britain Iuly'6, 1927 

